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Kunststoffschweißtechnik

WIDOS Einsteinstr. 5 Phone +49 (0) 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax +49 (0) 71 52 99 39 - 40 Website: http://www.widos.de Email: [email protected]

Headquarters: D-71254 Ditzingen-Heimerdingen Country Court Stuttgart HRB 200973 Managing director: Jürgen Dommer

Working Instructions Translation

Sheet welding machine

WIDOS PSM 10 XHS

Keep for further use!


Product identification

13.10.2014 Working instructions WIDOS PSM 10 XHS of 29

Type: WIDOS PSM 10 XHS Serial number: / Year of construction: see type label

Customers‘ entries

Inventory no.: Location:

Manufacturer’s address WIDOS W. Dommer Söhne GmbH Einsteinstraße 5

D-71254 Ditzingen-Heimerdingen

Phone: ++49 (0) 71 52 / 99 39 – 0 Fax: ++49 (0) 71 52 / 99 39 – 40

Order of spare parts and sales service:

Please directly order at manufacturer or subsidiaries: WIDOS WIDOS GmbH W. Dommer Söhne AG An der Wiesenmühle 15 St. Gallerstr. 93

D-09224 Grüna / Sachsen CH – 9201 Gossau

Phone: ++49 (0) 3 71 / 8 15 73 - 0 Phone: ++41 (0) 79 432 5737 Fax: ++49 (0) 3 71 / 8 15 73 - 20


Introduction


Purpose of the document These working instructions give you information about all important questions which refer to the construction and the safe working of your machine. Just as we are, you are obliged to engage in these working instructions, as well. Not only to run your machine economically but also to avoid damages and injuries. Should questions arise, contact our advisers in the factory or in our subsidiary companies. We will help you with pleasure.

According to our interest to continuously improve our products and working instructions, we kindly ask you to inform us about problems and defects which might appear in practical experience. Thank you.

Structure of the working instructions This manual is arranged in chapters which belong to the different using phases of the machine. Therefore the searched information can be easily found.

13.10.2014 WIDOS W. Dommer Söhne GmbH

Einsteinstraße 5 D-71254 Ditzingen-Heimerdingen

All rights reserved Reprinting only allowed with permission of the corporation.

Any changes are subject to technical innovations.


Contents


1. DESCRIPTION OF PRODUCT........................................................................................ 6

1.1. Usage and non-intended use................................... ............................................................6

1.2. Safety measures ..................................... ..............................................................................6

1.3. Conformity............................................ .................................................................................6

1.4. Designation of the product ................................... ...............................................................7 1.4.1. Technical data ....................................................................................................................7

1.4.1.1. WIDOS PSM 10 XHS General data.......................................................................7 1.4.1.2. Heating element.........................................................................................................7

1.4.2. Equipment and accessories (optional) ...............................................................................7

2. SAFETY RULES....................................... ....................................................................... 8

2.1. Explication of the different symbols....................... ............................................................8

2.2. Obligations of the operator................................. .................................................................9

2.3. Obligations of the worker ................................. ...................................................................9

2.4. Measures of organization ................................. ...................................................................9

2.5. Information about safety precautions ......................... .......................................................9

2.6. Instructions for the staff ............................... .......................................................................9

2.7. Dangers while handling the machine ............................ ...................................................10

2.8. Special dangers ........................................ ..........................................................................10 2.8.1. Danger of stumbling over electric wires ...........................................................................10 2.8.2. Danger of combustion by heating element and welding area ..........................................10 2.8.3. Danger of crushing between and near the clamping beams............................................11

2.9. Structural modifications on the machine....................... ..................................................11

2.10. Cleaning of the machine ................................... .................................................................11

2.11. Warranty and liability................................. .........................................................................11

3. FUNCTIONAL DESCRIPTION ............................. ......................................................... 12

4. OPERATING AND INDICATING ELEMENTS .................. ............................................ 13

4.1. Heating element ....................................... ...........................................................................14

5. STARTING AND OPERATING............................. ......................................................... 15

5.1. Starting............................................ .....................................................................................15

5.2. How to adjust the angle .................................. ...................................................................16 5.2.1. How to displace the clamping beams...............................................................................16

5.3. How to clamp sheets .................................... ......................................................................17

5.4. Welding process ......................................... ........................................................................17

6. WELDING TABLES..................................... .................................................................. 19

6.1. Welding logs and tables.................................... .................................................................19

7. MAINTENANCE / STORAGE / TRANSPORT .................. ............................................ 22


Contents


7.1. General............................................. ....................................................................................22

7.2. Clamping elements ...................................... .......................................................................22

7.3. Cleaning of the machine ................................... .................................................................22

7.4. Transport .............................................. ...............................................................................22

7.5. Disposal ............................................. ..................................................................................22

8. ELECTRIC DIAGRAM................................... ................................................................ 23

9. SPARE PARTS LIST................................... .................................................................. 24

9.1. Basic machine with motion ............................... ................................................................24

9.2. Heating element ....................................... ...........................................................................27

10. DECLARATION OF CONFORMITY.......................... ................................................ 29




1. Description of product This chapter gives important basic information about the product and its prescribed use. All technical details of the machine are put together as a general arrangement.

1.1. Usage and non-intended use

The WIDOS PSM 10 XHS is a workshop machine for the heating element butt welding of twin-wall sheets with thickness up to 60 mm and sheets with thickness up to 20 mm and length of plate up to 1000 mm made out of PE and PP.

Any other use of this machine is non-intended.

The machine is only to be used in a technically perfect condition as well as intended, safety- and danger-conscious in compliance with the working instructions and the relevant safety regulations (especially the regulations for the prevention of accidents). The described plastic welding machine may only be operated, maintained and repaired by persons who are trained and informed about the dangers. The manufacturer is not responsible for any damages caused by inappropriate handling or operation. For personal injuries, material and property damages resulting herefrom, only the user is responsible! Prescribed use also means:

• following all indications of these working instructions and

• performing the inspection and maintenance works.

1.2. Safety measures

In case of wrong use, wrong operation or wrong maintenance, the machine itself or products standing nearby can be damaged or destroyed. Persons in the endangered area may be injured. Therefore these working instructions have to be thoroughly read and the corresponding safety regulations must necessarily be observed.

1.3. Conformity

The machine corresponds in its construction to the valid recommendations of the European Community as well as to the European standard specifications. The development, manufacturing and mounting of the machine were executed very carefully.


Description of the product Chapter 1


1.4. Designation of the product

The product is designated by a type label. It contains the type of the machine, the serial number and the year of construction.

1.4.1. Technical data

1.4.1.1. WIDOS PSM 10 XHS General data

Welding load: maximal 300 kp / daN Twin-wall sheet size max: Sheet size max. (L x T):

1000 x 60 mm 1000 x 20 mm

Welding material: PE and PP Fuse protection: 16 A Line cross-section: 1,5 mm²

Dimensions (W x L x H): 810 x 1400 x 1200 mm Emissions: - By using the stated plastic materials during operation

within a temperature range of up to 260°C / 500°F, no poisonous vapors are generated.

Ambient conditions - Keep the workshop clean (no dust at the welding area) - If secured by an appropriate measurement that allowed

conditions for welding are indicated, it is possible to work in any outside temperature condition as far as the welder is not constrained in its manual skill.

- Avoid humidity - Avoid strong sunlight - Avoid strong wind

1.4.1.2. Heating element

Power: 2,6 kW Current: 11,3 A (± 10 %) Voltage: 230 V (± 10 %) Frequency: 50 Hz Surface: anti-stick coated Included components: - electronic temperature adjustment

- control lamp - connection cable with isolated ground plug

Order numbers and individual parts, please see „spa re parts lists“, when ordering please indicate seri al no. of the machine!

1.4.2. Equipment and accessories (optional)

The following tools and accessories are part of the original delivery:

each 2 Angle gauge 15° / 22,5° / 30° / 45° (for seg ment welding 30°-90°)

2 Combination spanner size 24




2. Safety rules A basic premise for working safely and without disturbances is the knowledge of the basic safety signs and rules.

• These working instructions provide you with the most important information to safely run the machine.

• The safety information has to be respected by all persons working with the machine.

2.1. Explication of the different symbols

The working instructions contain the following signs for certain situations:

This symbol means a possible danger to a person’s life and health.

• The disrespect of this indication may have heavy consequences for the health.

This symbol means a possibly dangerous situation.

• The disrespect of this indication may cause light injuries or damages of machine parts.

This symbol means a possibly dangerous situation due to hot surfaces.

• The disrespect of these indications may lead to heavy burns, respectively to ignition or even fire.

This symbol means a possibly dangerous situation by moving parts of the machine

• The disrespect of these indications may cause heavy crushing of parts of the body resp. damages of machine parts.

This symbol gives important indications for the proper use of the machine.

• The disrespect of this indication may lead to malfunctions and damages on the machine or on parts in the surrounding.

Under this symbol you get user hints and particularly useful information.

• It is a help for using all the functions on your machine in an optimal way and helps you to make the job easier.

The regu la t i ons f o r t he p reven t i on o f ac c i den t s a re va l i d (UVV) .


Safety rules Chapter 2


2.2. Obligations of the operator

The owner is obliged to only let persons work at the machine who

• know about basic safety and accident prevention rules and who are instructed in the handling of the machine

• the worker also must have read and understood the safety chapter of this manual and certify this by his signature.

The safety-conscious working of the staff has to be checked in regular intervals.

2.3. Obligations of the worker

Before working at the machine, all persons in charge of it oblige themselves:

• to follow the basic safety and accident protection rules.

• to have read and understood the safety chapter and the warnings in this manual and to confirm by their signature that they have understood well.

• to inform themselves about the functions of the machine before using it.

2.4. Measures of organization

• The necessary personal protection equipment is to be provided by the operator.

• All available safety equipment is to be inspected regularly.

2.5. Information about safety precautions

• The working instructions are to be permanently kept at the place of use of the machine. They are to be at the operator‘s disposal at any time and without effort.

• In addition to the manual, the common valid and the local accident protection rules and regulations for the environmental protection must be available and followed.

• All safety and danger indications on the machine have to be in a clear, readable condition.

• Every time the machine changes hands or is being hired to a third person, the working instructions are to be sent along with the machine and their importance is to be emphasized.

2.6. Instructions for the staff

• It must be clearly defined who is responsible for transport, mounting and dismounting, starting the operation, setting and tooling, operation, maintenance and inspection, repair and disassembly.

• Only skilled and trained persons are allowed to work at the machine.

• A person who is being trained may only work at the machine under supervision of an experienced person.




2.7. Dangers while handling the machine

The WIDOS PSM 10 XHS is constructed according to the latest technical standard and the acknowledged technical safety rules.

However, dangers for the operator or other persons standing nearby may occur. Also damages of the machine itself or of other parts are possible. The machine has to be only used

• according to the prescriptions

• in technically safe condition

Disturbances which may affect the safety of the machine must be eliminated immediately.

Only skilled persons are allowed to work at electric appliances.

• The electric equipment of the machine has to be checked regularly. Loose connections and damaged cables have to be replaced immediately.

• The heating element has to be protected against rain and dripping water.

• According to VDE 0100, the machine may only be applied on building sites via power distributors with FI security switch.

2.8. Special dangers

2.8.1. Danger of stumbling over electric wires

• Make sure that nobody has to step over the cable to the heating element.

2.8.2. Danger of combustion by heating element and welding area

You can burn parts of your body and inflammable materials can also ignite!

The heating element can be heated up to more than 250°C / 482°F !

• Do not leave the heating element unsupervised.

• Do not touch the surface of the heating element.

• Take enough safety distance to inflammable materials.

• Do wear safety gloves.

• Pay attention that nobody is in the area of the heating element.

• While cleaning the heating element with cleaning agents (e.g. with PE-cleaning agent) there is the danger of igniting. Therefore pay attention that the flashpoint is smaller than the temperature of the heating element, do not put inflammable materials next to it (e.g. cigarette).




2.8.3. Danger of crushing between and near the clam ping beams

You can crush, grip or squeeze your fingers.

• While closing the clamping beams do not put parts of your body between beams and sheet.

• While the tables are driving together do not put parts of your body between beams and sheets.

2.9. Structural modifications on the machine

• No modifications, extensions or reconstructions may be made on the machine without permission of the manufacturer. In case of disrespect the warranty or liability will expire.

• Machine parts which are not in a perfect condition are to be immediately replaced.

• Only use original WIDOS spare and wear parts.

• In case of purchase orders please always indicate the machine number !

2.10. Cleaning of the machine

The materials you use for cleaning the machine have to be properly treated and have to be appropriately disposed, especially:

• when cleaning with solvents

• when greasing with oil and grease.

2.11. Warranty and liability

Our „General Sales and Delivery Conditions“ are principally valid. They are at the owner's disposal at the latest when signing the contract. Warranty and liability demands referring to damages of persons or objects are suspended if they are caused by one or several of the following reasons:

• not using the machine according to the prescriptions

• improper transport, building-up, starting and operating the machine and maintenance

• ignoring the information given in this manual

• structural changes at the machine without permission

• unsatisfactory checking of machine parts which are worn out

• repairs performed in an inexpert way

• catastrophes by external influence and Acts of God.




3. Functional description A l l i n t e rna t i ona l and na t i ona l p rocess gu ide l i nes a re t o be bas i ca l l y f o l l ow ed ! By using the clamping beams the plastic sheets are clamped. Afterwards the position of the sheets are checked and if necessary changed.

Now the heating element is slewed in and the sheets are pressed on the heating element at a defined pressure. This process is called "adjusting" .

The applied power can be seen on the scale you find on the machine of the left side.

Having reached the mandatory bead height the pressure is reduced, the heating time begins. This time is used to reach the welding temperature at the sheet ends. After the ending of the heating-up, the tables drive apart, the heating element quickly slews out of the machine and the tables drive together again, we call this change-over time . The sheets are joined at the needed welding pressure and cool down under pressure (cooling time ).

The welding joint can be clamped out and the welding process is completed. Image of a heating element butt welding:

heating element heats the sheets up to welding temperature

completed weld joint with bead on top and below




4. Operating and indicating elements

No. Denomination Function 1 Heating element - to heat up the sheets 2 Clamping beam, left side - to clamp the sheet 3 Clamping nuts - clamping / releasing of the clamping beams 4 Hinged plate, left side - support for the plastic sheet 5 Table, left side flexible - to drive / shut the workpiece 6 Range - display of applied welding force.

- max. display: 325 kp. 7 Clamping lever, left side - to fix the angle 8 Lever - to slew the heating element up and downwards 9 Clamping beam, right side - to clamp the sheet

10 Hinged plate, right side - support for the plastic sheet 11 Clamping lever, right side - to fix the angle 12 Crank - to drive the flexible slide to and fro.

- to apply the adjusting and joining force.

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Operating and indicating elements Chapter 4


4.1. Heating element

No. Denomination Function 13 On / off switch,

illuminated in red - as soon as the heating element is turned on, it is heated up. - lamp is red if connected to the mains

14 Display + induction regulator

- adjustment of temperature of the heating element

15 Control lamp, green We differ between 3 status: • Off : signal for the state that the heating element does not heat

up or cool down at the moment.

• Blinking: The temperature of the heating element stays stable. This is realized by the pulse-interval relation.

• ON: signal for the state that the heating element is heated up at the moment. The desired temperature is not yet reached.

16 Connection cable - cable for the connection with the local power supply 230 V / 50 Hz, fuse protection 16 A

The heating element is shown in welding position. Slew lever (8) below in arrow direction to bring the heating element into basic position.

13

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16

(8)




5. Starting and operating The instructions of this chapter are supposed to guide you in the operation of the machine and lead you during the appropriate starting of the machine. This includes: - the safe operation of the machine; - using all the possible options of the machine; - economic operation of the machine.

5.1. Starting

• The machine must be assembled prior to welding in a way that the crank may be rotated properly and that the heating element may be slewed up and down.

The machine only has to be introduced and used by skilled persons. For their qualification they can pass an exam of plastic welding according to DVS and DVGW.

• In dangerous situations for man and machine you have to immediately disconnect the machine from the mains plug.

• Having finished the welding work and during intervals you have to turn off the machine. Furthermore you have to control that no unauthorized person can use the machine

• Protect machine against humidity!

• The use on building sites is only permitted when respecting VDE 0100 and using current distribution with FI-safety-switch.

• Connect the heating element with mains (230 V / 50 Hz / 16 A).

Carefully install the electric cable (danger of stumbling)!

• Pay attention to environmental conditions: − The welding process may not take place in case of direct insolation.

• If local temperature is under 5°C / 41°F the follo wing measures have to be taken: − if necessary heat-up sheet ends.

• Take measures against rain, wind and dust.


Starting and operating Chapter 5


5.2. How to adjust the angle

Illustration showing the machine of the angle. In order to clamp the sheets for segment welding at an angle of 30° - 90°, you must adjust the requested angle first.

• Release both clamping levers at the hinged plate in the front and rear.

• Swing both hinged plates upwards and shift the angle gauge up to limit stop.

• Fix both clamping levers again.

Always adjust the same angle on both sides!

5.2.1. How to displace the clamping beams

The clamping beam should fix the sheet as close to the welding spot as possible. Depending on the angle adjustment, it may be possible that you must displace the clamping beam to the outside in order that it does not touch the heating element during welding. The hinged plate features three drill holes for the positioning of the clamping beam. Illustration showing clamped twin-wall sheets:

• If necessary detach the clamping nuts, the counternuts and unscrew the spindle.

• Fix the threaded spindle in another drill hole. (small angle = inner drill hole; large angle = outer drill hole)

Three drill holes for setting the angles

Insert plastic sheet here

Angle gauge

Clamping beam

Hinged plate

Clamping nut

Angular size: gauge 15 for angle 30°

gauge 22,5 for angle 45° gauge 30 for angle 60° gauge 45 for angle 90°

Clamping lever




5.3. How to clamp sheets

• Detach the hexagon socket nuts, lift the clamping beam and shift the sheet between hinged plate and clamping beam for the welding.

• Position the sheet for the welding in a way that it slightly overlaps (in parallel manner) the hinged plate to the inside (see arrow in upper image).

• Clamp the sheet by tightening the hexagon socket nuts.

• Clamp the second welding sheet and adjust both sheets to each other. For this purpose drive the tables together by turning the crank. If necessary you may slightly release the hexagon socket nuts and position the sheets exactly by shifting. Afterwards, tighten the hexagon socket nuts again.

• Drive the tables apart again; now you may start welding.

5.4. Welding process

Bas i ca l l y , t he resp ec t i ve l y va l i d w e ld i ng gu ide l i ne s have t o be respec ted ( ISO / CEN / DVS . . . ) .

• If you want to weld an angle, adjust the angle by the corresponding angle gauge (chapter: 5.2).

• You must prepare the workpieces for welding in a way that the surfaces: - are clean, especially free of grease; - are plane and parallel; - have the requested angle.

• For the protection against combustion wear safety gloves!

• Keep a stop watch ready for taking the actual time of heating up and cooling down.

• Keep a table ready where you can find the mandatory parameters to be used (time and force) for the dimensions of the sheet to be welded.

In order to weld angles, you must multiply the bead-up / welding force by the corresponding factor (chapter: 6.1).

• The surface of the heating element has to be clean, especially free of oil, and has to be cleaned before every welding process resp. if it is dirty with non-fibering paper or cleaning agent (e.g. PE - cleaner). The ant-stick coating of the heating element has to be intact.

• Turn the heating element on by its switch (chapter: 4.1, no: 13) and adjust the needed welding temperature at the adjusting screw at the handle (14). - When the green control lamp (15) is blinking, the desired temperature is reached and stays stable with the help of a pulse-interval relation.

• Release the clamping nuts, lift the clamping beam and put the sheet parallel to the hinged plate between clamping beam and hinged plate (see chapter: 5.3).

• Fix the sheet by the clamping nuts.

• Fix the second plate on the opposite side.

• Drive the slides together by the crank.




• Check sheet displacement and crack at the ends of the nudging sheets. According to DVS 2207 the displacement of the tolerated crack may not be larger than 0,5 mm. - The displacement compensation is realized by opening the clamping nuts and displacing

of the sheets. Afterwards refasten the clamping nuts.

• Take the adjusting force for the sheet dimensions to be welded out of the table.

• Heating up time, max. change-over time, cooling-down time and height of bead for the sheet dimensions to be welded have to be taken out of the table.

• Drive the slide a little bit open.

• Slew in the cleaned heating element when it has reached the desired temperature. If necessary wait until the control lamp smoothly blinks.

• Drive the slides with identified adjusting force and hitchless together. The reached force can be seen on the force range (6) of the slide of the left side. Having reached the mandatory surrounding bead height reduce the force (heating up force = appr. 10 % of adjusting force).

• Now the heating up time begins. Press the stopwatch and compare the actual time with the desired time of the table.

• Having finished the heating up time drive the slide a little bit open, slew out the heating element as fast as possible and drive the slides hitchless together. The maximum time for this process is given by the value for the change-over time indicated in the table.

• After the erection of the welding force press the stopwatch. During the cooling down adjust the force if necessary once again (the cooling down force is the same as the adjusting force).

• After the cooling down time has elapsed remove the force.

• Remove the clamping nuts and clamping beams and take out the welded piece.

• Then drive the slides open.

Welding is completed.




6. Welding tables

The following welding tables are to be used exclusively for plastic sheets out of PE and PP.

In order to weld other profiles, like e.g. twin-wall sheets, you must comply with the respectively valid national and international welding prescriptions (ISO / CEN / DVS...).

6.1. Welding logs and tables

If welding angles, the welding surface of the sheet and thus the necessary forces changes. Calculate the necessary force as follows:

• Take the prescribed value for adjusting or cooling from the table.

• Multiplicate the force value with factor /cos (angle). This will give the following factors:

Welding 15° (chamfered sheet with 7,5°): 1,01 Welding 22,5° (chamfered sheet with 11,25°): 1,0 2 Welding 30° (chamfered sheet with 15°): 1,04 Welding 45° (chamfered sheet with 22,5°): 1,08 Welding 60° (chamfered sheet with 30°): 1,15 Welding 90° (chamfered sheet with 45°): 1,41

• Add the motional force as usual.

All the other welding parameters remain as usual.

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Table for PE Heating up time = 10 x wall thickness [sec]

Cooling down time under joining force = 1,333 * wall thickness [min]

The standard value for the heating element temperature is between 200° C - 220° C.

J o i n i n g f o r c e [kp]

For smaller wall thickness higher temperatures should be relized.

The standard value for the heating element temperature is 220° C.

The change-over and pressure building up time should be realized with PE 100 as fast as possible!

For the given adjusting and welding force the movement force of the welding slide has to be added! 1 kp = 10 N

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193

199

205

211

120

126

132

137

143

149

154

160

166

172

177

183

189

194

200

114

119

125

130

136

141

146

152

157

163

168

173

179

184

190

108

113

118

123

128

133

138

143

148

154

159

164

169

174

179

101

106

111

116

121

125

130

135

140

145

149

154

159

164

169

95

100

104

109

113

118

122

127

131

136

140

145

149

154

158

89

93

97

101

106

110

114

118

122

127

131

135

139

143

148

82

86

90

94

98

102

106

110

114

118

121

125

129

133

137

76

80

83

87

91

94

98

101

105

109

112

116

119

123

127

70

73

76

80

83

86

90

93

96

100

103

106

109

113

116

64

67

70

73

76

79

82

85

88

91

94

97

100

103

106

57

60

63

65

68

71

73

76

79

82

84

87

90

92

95

51

53

56

58

61

63

65

68

70

73

75

77

80

82

85

45

47

49

51

53

55

57

59

61

64

66

68

70

72

74

38

40

42

44

46

47

49

51

53

55

56

58

60

62

64

32

34

35

37

38

40

41

43

44

46

47

49

50

52

53

26

27

28

29

31

32

33

34

35

37

38

39

40

41

43

19

20

21

22

23

24

25

26

27

28

28

29

30

31

32

13

14

14

15

16

16

17

17

18

19

19

20

20

21

22

7

7

7

8

8

8

9

9

9

10

10

10

10

11

11

420

440

460

480

500

520

540

560

580

600

620

640

660

680

700

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20

2

19

2

18

2

17

2

16

2

15

2

14

2

13

2

12

1,5

11

1,5

10

1,5

9

1,5

8

1,5

7

1,5

6

1

5

1

4

1

3

0,5

2

0,5

1

0,5

PE 80

PE 100

Tickness

Bead height

Lenght









217

223

229

235

241

247

253

259

265

271

277

283

289

295

301

206

211

217

223

229

234

240

246

251

257

263

268

274

280

286

195

200

206

211

217

222

227

233

238

244

249

254

260

265

271

184

189

194

199

205

210

215

220

225

230

235

240

245

250

256

173

178

183

188

193

197

202

207

212

217

221

226

231

236

241

163

167

172

176

181

185

190

194

199

203

208

212

217

221

226

152

156

160

164

169

173

177

181

185

190

194

198

202

206

211

141

145

149

153

157

160

164

168

172

176

180

184

188

192

196

130

134

137

141

145

148

152

155

159

163

166

170

173

177

181

119

123

126

129

133

136

139

142

146

149

152

156

159

162

166

109

112

115

118

121

124

127

130

133

136

139

142

145

148

151

98

100

103

106

109

111

114

117

119

122

125

127

130

133

136

87

89

92

94

97

99

101

104

106

109

111

113

116

118

121

76

78

80

82

85

87

89

91

93

95

97

99

101

103

106

65

67

69

71

73

74

76

78

80

82

83

85

87

89

91

55

56

58

59

61

62

64

65

67

68

70

71

73

74

76

44

45

46

47

49

50

51

52

53

55

56

57

58

59

61

33

34

35

36

37

37

38

39

40

41

42

43

44

45

46

22

23

23

24

25

25

26

26

27

28

28

29

29

30

31

11

12

12

12

13

13

13

13

14

14

14

15

15

15

16

720

740

760

780

800

820

840

860

880

900

920

940

960

980

1000

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201,5

21

25

29

33

37

41

45

49

53

57

61

65

69

73

77

81

191

20

23

27

31

35

39

42

46

50

54

58

61

65

69

73

77

181

19

22

26

29

33

37

40

44

47

51

55

58

62

65

69

73

171

18

21

24

28

31

35

38

41

45

48

52

55

58

62

65

69

161

17

20

23

26

29

33

36

39

42

45

49

52

55

58

61

65

151

16

19

22

25

28

31

34

37

40

43

46

49

52

55

58

61

141

15

17

20

23

26

29

31

34

37

40

43

45

48

51

54

57

131

14

16

19

21

24

27

29

32

34

37

40

42

45

47

50

53

121

13

15

17

20

22

25

27

29

32

34

37

39

41

44

46

49

111

12

14

16

18

20

23

25

27

29

31

34

36

38

40

42

45

101

11

13

15

17

19

21

23

25

27

29

31

33

35

37

39

41

90,9

10

11

13

15

17

19

20

22

24

26

28

29

31

33

35

37

80,8

9

10

12

13

15

17

18

20

21

23

25

26

28

29

31

33

70,7

8

9

10

12

13

15

16

17

19

20

22

23

24

26

27

29

60,6

7

8

9

10

11

13

14

15

16

17

19

20

21

22

23

25

50,5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

40,5

5

5

6

7

8

9

9

10

11

12

13

13

14

15

16

17

30,5

4

4

5

5

6

7

7

8

8

9

10

10

11

11

12

13

20,5

3

3

3

4

4

5

5

5

6

6

7

7

7

8

8

9

Thickness

Bead hight

Lenght

100

120

140

160

180

200

220

240

260

280

300

320

340

360

380

400

Table for PP Heating up time = 15 x wall thickness [sec], for 2 - 4 mm wall thickness; and 16 x wall thickness [sec], for 5 - 10 mm wall thic

Cooling down time under joining force = 2,0 x wall thickness [min], for 2 - 4 mm; and 1,75 x wall thickness [min] for >4 - 10 mm

The standard value for heating element temperature is 210° C ± 10 °C, for smaller wall thickness higher temperatures have to be realized.



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201,5

191

181

171

161

151

141

131

121

111

101

90,9

80,8

70,7

60,6

50,5

40,5

30,5

20,5

Thickness

Bead hight

Lenght






85

89

93

97

101

105

109

113

117

121

125

129

133

137

141

80

84

88

92

96

99

103

107

111

115

118

122

126

130

134

76

80

83

87

91

94

98

101

105

109

112

116

119

123

127

72

75

79

82

86

89

92

96

99

103

106

109

113

116

120

68

71

74

77

81

84

87

90

93

97

100

103

106

109

113

64

67

70

73

76

79

82

85

88

91

94

97

100

103

106

59

62

65

68

71

73

76

79

82

85

87

90

93

96

99

55

58

60

63

66

68

71

73

76

79

81

84

86

89

92

51

53

56

58

61

63

65

68

70

73

75

77

80

82

85

47

49

51

53

56

58

60

62

64

67

69

71

73

75

78

43

45

47

49

51

53

55

57

59

61

63

65

67

69

71

38

40

42

44

46

47

49

51

53

55

56

58

60

62

64

34

36

37

39

41

42

44

45

47

49

50

52

53

55

57

30

31

33

34

36

37

38

40

41

43

44

45

47

48

50

26

27

28

29

31

32

33

34

35

37

38

39

40

41

43

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

17

18

19

20

21

21

22

23

24

25

25

26

27

28

29

13

14

14

15

16

16

17

17

18

19

19

20

20

21

22

9

9

10

10

11

11

11

12

12

13

13

13

14

14

15

420

440

460

480

500

520

540

560

580

600

620

640

660

680

700

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201,5

191

181

171

161

151

141

131

121

111

101

90,9

80,8

70,7

60,6

50,5

40,5

30,5

20,5

Thickness

Bead hight

Lenght






145

149

153

157

161

165

169

173

177

181

185

189

193

197

201

137

141

145

149

153

156

160

164

168

172

175

179

183

187

191

130

134

137

141

145

148

152

155

159

163

166

170

173

177

181

123

126

130

133

137

140

143

147

150

154

157

160

164

167

171

116

119

122

125

129

132

135

138

141

145

148

151

154

157

161

109

112

115

118

121

124

127

130

133

136

139

142

145

148

151

101

104

107

110

113

115

118

121

124

127

129

132

135

138

141

94

97

99

102

105

107

110

112

115

118

120

123

125

128

131

87

89

92

94

97

99

101

104

106

109

111

113

116

118

121

80

82

84

86

89

91

93

95

97

100

102

104

106

108

111

73

75

77

79

81

83

85

87

89

91

93

95

97

99

101

65

67

69

71

73

74

76

78

80

82

83

85

87

89

91

58

60

61

63

65

66

68

69

71

73

74

76

77

79

81

51

52

54

55

57

58

59

61

62

64

65

66

68

69

71

44

45

46

47

49

50

51

52

53

55

56

57

58

59

61

37

38

39

40

41

42

43

44

45

46

47

48

49

50

51

29

30

31

32

33

33

34

35

36

37

37

38

39

40

41

22

23

23

24

25

25

26

26

27

28

28

29

29

30

31

15

15

16

16

17

17

17

18

18

19

19

19

20

20

21

720

740

760

780

800

820

840

860

880

900

920

940

960

980

1000

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13.10.2014 Working instructions WIDOS PSM 10 XHS Page 22 of 29

7. Maintenance / storage / transport 7.1. General

• Damaged parts have to be immediately replaced, in particular be careful with electric parts, dirt and humidity are very good conductors.

• In case of repair do only use original WIDOS – spare parts .

• Control resp. refasten all screwed connections if loose every 3 months .

All maintenance and repair work must be executed with the machine being switched off. Thereby, the machine has to be protected against unintentional activation.

Prescribed maintenance and repair works are to be executed in due time. DVS recommends repair works after one year. Machines which are loaded above the average, the checking cycle should be shortened. The works have to be executed by company WIDOS GmbH or by one of its authorized representatives.

The linear guides must be cleaned every week , e.g. with a brush. Check the linear guide carriages every 3 months and grease them over the lubricating nipple if necessary. Dirty guides may cramp and run heavily.

7.2. Clamping elements

In order to warrant a long lifetime, threaded spindles and joint pieces for clamping the sheets should be regularly cleaned and greased.

7.3. Cleaning of the machine

The materials you use for cleaning the machine have to be properly treated and have to be appropriately disposed of, especially:

• when cleaning with solvents

• when greasing with oil and grease.

7.4. Transport

• The machine has to be handled carefully.

• Protect against shocks and hits.

7.5. Disposal

The machine and wear parts have to be disposed of at the end of their useful life according to the common Waste Management Laws in a proper and environmentally sound manner.




8. Electric diagram




9. Spare parts list 9.1. Basic machine with motion

12 - 14

1 - 3

5

6 - 7

8

15 - 20 21 - 23

24

25

26

9 - 11

31 - 34

35

36 - 37

27 - 28

38

29 - 30

39 40

41 - 42

43 - 45

46 - 48

49

50

51 - 52


Spare parts list Chapter 9


Image: Basic machine from below, without base frame.

53 - 56 57 - 60

71 - 72

73

69 - 70

68

84 - 87 88 89

64 - 67 61 - 63

90 - 91

77 - 78

79 - 80

81 - 82

83

74 - 76



Basic machine with frame WIDOS PSM 10

Pos. Denomination Piece Order no. 1 Clamping beam for hinged plate 2 82176822 Bow-type handle (BG565201) 4 on request3 Pan-head screw M 6x20 DIN 912 8 0912F0204 Washer M 6 DIN 125 8 0125F5 Threaded spindle 4 821768816 Hexagon nut M 16 DIN 934 4 0934P7 Washer M 16 DIN 9021 4 9021P8 Hexagon nut M 16 DIN 936 4 0936P9 Hinge 10 on request

10 Flat-head screw M 4x12 DIN 7991 60 7991D01211 Hinged plate 2 821768612 Basis plate left 1 8217681113 Hexagon-head screw M 8 x 16 DIN 933 2 0933F01614 Washer M 8 DIN 9021 2 0921F15 Heat-absorbing sheet 2 821761616 Bushing for heat-absorbing sheet 8 091173217 Rosette 8 ROSM618 Flat-head screw M 6 x 25 DIN 7991 8 7991f02519 Washer M 6 DIN 9021 8 9021F20 Hexagon nut M 6 DIN 934 8 934F21 Sub frame 1 821160122 Pan-head screw M 8 x 65 DIN 912 4 0912H06523 Washer M 8 DIN 125 4 0125H24 Latesal casing for base frame 2 821160625 Rear casing for base frame 1 821160726 Base plate for base frame 1 821160527 Flat-head screw M 5 x 10 DIN 7991 26 7991E01028 Rosette 26 ROSM529 Sheet for sub frame 1 821160230 Edge protection, 800 mm long 1 on request31 Angle gauge 15° 2 8217685-1532 Angle gauge 22,5° 2 8217685-22,533 Angle gauge 30° 2 8217685-3034 Angle gauge 45° 2 8217685-4535 Basis plate right 1 821768136 Hexagon-head screw M 8 x 16 DIN 933 2 0933F01637 Washer M 8 DIN 9021 2 0921F38 Screw cap 80x40x5 4 J020439 Axis for hinged plate 4 821768440 Support fishplate for hinged plate 4 821768341 Clamping lever M10x30 4 on request42 Washer M10 DIN 9021 4 9021J43 Pointer 1 38016744 Flat-head screw M 6 x 8 DIN 7991 1 7991F00845 Pressure range 1 380130246 Angle 1 8211604

13.10.2014 Working instructions WIDOS PSM 10 XHS Page 26 / 1 of 29



Basic machine with frame WIDOS PSM 10

Pos. Denomination Piece Order no.

47 Hexagon-head screw M 6 x 18 DIN 933 2 0933F01848 Washer M 6 DIN 9021 2 9021F49 Bolt for handwheel 1 821161950 Handwheel DIN 950-GG-160-B15-D 1 BH16051 Washer M 14 DIN 125 1 0125N52 Hexagon nut M 14 DIN 934 1 0934N53 Beam, at the back 1 38010254 NSK-guide rail 500 mm 1 L2050055 Pan-head screw M 5x16 DIN 912 18 0912E01656 Cap 18 L2050157 Support, movable 1 38010358 Thread insert M 8 x 9 5 GEWK-M859 NSK-guide carriage 4 L20CLZ60 Pan-head screw M 5x12 DIN 912 8 0912E01261 Support, fix 1 38010462 Thread insert M 8 x 15 9 GEW-M863 Pan-head screw M 8x40 DIN 912 6 0912H04064 Threaded spindle 1 38011365 Hexagon nut M 12 DIN 934 1 0934L66 Washer M 12 DIN 125 4 0125L67 Stop nut 2 38011468 Bevel gear with threaded bolt 1 380161269 Washer for threaded rod 1 380168170 Pan-head screw M 8 x 15 DIN 912 1 0912H01571 Bevel gear, big 1 380169272 Grub screw M 8 x 12 DIN 916 1 0916H01273 Nut for gearwheel shafting collar 1 38010974 Shafting for crank 1 380168275 Parallel pin 6 m6 x 30 DIN 7 1 0007F03076 Collar for gearwheel shafting 1 38011777 Guiding for shafting 1 38016578 Pan-head screw M 8 x 50 DIN 912 2 0912H05079 Shafting for spring 2 38016680 Pressure spring 2 FE03381 Plate for spring support 1 380164182 Flat-head screw M 8 x 25 DIN 7991 2 7991H02583 Beam, at the front 1 38010184 Bearing for threaded bolt 1 38016385 Ball-bearing 6005 ZZ 2 L6005Z86 Sleeve intermediate bearing 1 38016287 Pan-head screw M 8 x 70 DIN 912 2 0912H07088 Nut for bevel gear bolt 1 380161189 Threaded rod TR 16x4 1 38016890 Coupler plate 1 380164291 Pan-head screw M 8 x 25 DIN 912 1 0912H025 -- Data plate 1 on request

13.10.2014 Working instructions WIDOS PSM 10 XHS Page 26 / 2 of 29


Spare Parts list Chapter 9


9.2. Heating element

20

19

24 - 26

27

33

30 - 32

28 / 29

36 - 37

38 - 39

23

34 / 35

21

22

1

2 - 5 14

6 - 9

10

15

11 - 13

16 - 18



Heating Element WIDOS PSM 10

Pos. Name Piece Order no.

1 Heatingelement for PSM 10 (effective depth 100 mm) 1 8215630Heating plate in exchange (effective depth 100 mm) 1 on requestHeating cartridge Ø16 x 1135 mm, 1,3kW, 230V 1 HPA161135

2 Tapped bushing Ø12 x 24 / M6 2 HGEW-M623 Insulator 2 82156044 Distance bush 2 82156095 Pan-head screw M 8 x 60 DIN 912 2 0912H0606 Connecting rod 3 821560537 Pan-head screw M 8 x 12 DIN 912 8 0912H0128 Washer M 8 DIN125 8 0125H9 Bolt for heating element holder 4 8215607

10 Lever 1 8215606311 Handle with insert nut 1 H090612 Hexagon nut M 8 DIN 934 1 0934H13 Washer M 8 DIN 125 1 0125H14 Heating element holder 1 821560315 Support for heating element 1 821560216 Linear guide carriage 2 L20CLZ17 Distance bush 4 821560818 Pan-head screw M 5 x 30 DIN 912 4 0912E03019 Switch on/off, red 1 H090320 Handle case 1 H0907721 Antilink grommet 1 EKT0822 Pan-head screw M 4 x 70 DIN 912 3 0912D07023 Connecting cable 1 EK322024 Turning knob with slot 1 H0907525 Scale 180 - 280° (d 33) 1 H0907426 Electric control GZ4, 230 V 2 H091822027 Control lamp, green 1 H210528 Spring lock washer M 6 DIN 127 2 0127F29 Pan-head screw M 6 x 70 DIN 912 2 0912F07030 Triac with heat sink 1 H0908131 Pan-head screw M 4x70 DIN 912 3 0912D07032 Insulating washer 1 02358433 Joining piece 1 02358234 Sensor PT 1000 1 H0908235 Holder for sensor 1 02353636 Insulating piece 2 09250337 Insulating piece 1 82151538 End cap 1 821561439 Lens-head screw M 3x8 DIN 7985 4 7985C010

13.10.2014 Working instruction WIDOS PSM 10 XHS Page 28 of 29


WIDOS Einsteinstr. 5 Phone ++49(0) 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49(0) 71 52 99 39 - 40 info @ widos.de http://www.widos.de


10. Declaration of conformity in the sense of the EC-guideline, EC Machinery Dir ective 2006/42/EC

Company: WIDOS GmbH Einsteinstr. 5 D-71254 Ditzingen-Heimerdingen declare under own responsibility that the product Plastic welding machine WIDOS PSM 10 XHS

to which this declaration refers, corresponds to the following norms and normative documents:

1. DIN EN ISO 12100 – 1 und 2 (substitute for DIN EN 292 parts 1 and 2) Safety of machines, basic terminology, gen. design guidelines

2. DIN EN 60204.1 Electric equipment of industrial machines

3. DIN EN 60555, DIN EN 50082, DIN EN 55014 Electro-magnetic compatibility

The technical documentation is completely available.

The working instructions are available in the language German and English. Ditzingen-Heimerdingen, the 13.10.2014

Martin Dommer (Technical director)

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